Method and system for providing an insulative wall structure

ABSTRACT

A method and system for providing an insulative wall structure. The insulative wall structure includes first and second vertical longitudinal supports, which are separated horizontally, creating a space therebetween. The insulative wall structure also includes a thermal insulation member placed within the space between the first and second vertical longitudinal supports so that it is engaged with both of the vertical longitudinal supports. The resulting wall structure reduces thermal transmissions through the first and second vertical longitudinal supports.

TECHNICAL FIELD

The present invention is directed to wall structures in construction, and more particularly, to an insulated wall structure and methods for its construction.

BACKGROUND OF THE INVENTION

A typical wall panel used in construction today includes a frame comprising load bearing members spaced vertically apart from each other and bound by upper and lower elements. The frame is generally made from wood or metal, however, other materials may be used. In general, a wood frame is trimmed to the desired dimensions to form the frame, and a metal frame is bent to the desired dimensions.

Once the frame is erected, insulation is installed into the frame. Typically, fiberglass insulation is used. The fiberglass insulation is a soft material and is placed between the load bearing members. At the junction where the fiberglass meets load bearing members, there are often small voids. These voids allow for thermal transmission reducing the insulation effectiveness of the wall. Similarly, the voids provide a path for sound to transmit through the wall. Additionally, because the fiberglass insulation is a soft material, it often sags after being installed into the frame due to gravity. This creates more voids between the insulation and the load bearing members and reduces the thermal properties and sound reducing properties of the wall panel even further.

While such wall panels have served in the construction of buildings for decades, today's greater demand for thermal efficiency has affected the choice of building materials being used. Additionally, wall structures capable of absorbing sound waves to decrease noise levels heard through the walls are also in demand.

Therefore, there is a need for wall structures in the construction of buildings that are capable of providing thermal efficiency and reducing sound transmission at a reasonable cost.

SUMMARY OF THE INVENTION

The present invention is directed toward an insulated wall structure and methods for its construction. In one aspect of the invention, the wall structure comprises first and second vertical longitudinal supports, where the supports are separated horizontally and create a space therebetween. A rigid insulation member is placed within the space and bonded to the first and second vertical longitudinal supports.

According to a second aspect of the invention, the method for erecting a wall structure includes bonding a first end of a rigid insulation member to a first longitudinal support and bonding a second end of the rigid insulation member to a second longitudinal support.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic drawing of a wall structure according to one embodiment of the invention.

FIG. 2A is a schematic drawing of a wall structure without openings according to one embodiment of the invention.

FIG. 2B is a cross sectional view of the wall structure in FIG. 2A according to one embodiment of the invention.

FIG. 3A is a schematic drawing of a wall structure without openings according to one embodiment of the invention.

FIG. 3B is a top down view of the wall structure in FIG. 3A according to one embodiment of the invention.

FIG. 4 is a cross section of an insulation member according to one embodiment of the invention.

FIG. 5 is a cross section of a hat channel for creating an air gap between an outer surface of a wall structure and an exterior surface of a building according to one embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Embodiments of the present invention are directed toward wall structures in construction, and more particularly, one or more embodiments are directed to an insulated wall structure and methods for its construction. Certain details are set forth below to provide a sufficient understanding of the embodiments of the invention. However, it will be clear to one skilled in the art that various embodiments of the invention may be practiced without these particular details.

FIG. 1 is a schematic drawing of a wall structure 100 according to one embodiment of the invention. The wall structure 100 includes insulation members, such as 120, between load bearing members, such as 110 a and 110 b. The wall structure 100 includes many wall bearing members and insulation members as can be seen in FIG. 1, however, in the interest of brevity only load bearing members 110 a and 110 b and insulation member 120 will be described.

Insulation member 120 is placed between and in contact with load bearing member 110 a and load bearing member 110 b and has been called an Enviro-Envelope System. The load bearing members 110 a and 110 b primarily provide support for vertical loading, such as weight borne by a truss. In addition, however, the load bearing members 110 may provide horizontal support for loads that transverse a member within the wall structure 100. The wall structure 100 in FIG. 1 is an external wall structure for being installed within a building structure (not shown). However, as will be clear to a person of ordinary skill in the art, the wall structure 100 may also be used for internal wall structures.

The insulation member 120 is bonded to the load bearing members 110 a and 110 b. For instance, the insulation member 120 may be secured to the load bearing members 110 a and 110 b by an adhesive. In one embodiment, the insulation member 120 is a rigid material, such as polystyrene. In another embodiment, the insulation member 120 is a semi-rigid material, such as a rubber based material. The rigid or semi-rigid insulation member may improve the structural integrity of the wall structure 100. The wall structure 100 is bound on top by a top track member 140 and is bound on bottom by a bottom track member 142.

The wall structure 100 has a window opening 130 and door opening 132, however, other openings may be used with the wall structure 100. The height of the wall structure 100 varies and often depends on the building structure in which the wall structure 100 will be installed. Typically, the height of the wall structure 100 will vary between approximately 8-40 feet. For instance, in one embodiment, the height of the wall structure 100 is about 10 feet. In another embodiment, the wall structure 100 is approximately 30 feet tall. Above an opening, is an insulative beam providing support for the downward vertical load that is applied from above. For instance, beam 134 is above the window opening 130 and is secured to insulative member 110 a by connection 136. The beam comprises two C-channels or U-channels with a rigid material between them, such as polystyrene. The channels may be secured to the rigid material by an adhesive. The beam and connection are further described in U.S. Pat. No. 5,678,381, which is incorporated for all purposes in its entirety herein. Along the sides of the opening are king studs, which support the beam. The king studs consist of two U-channel or C-channel load bearing members facing one another with a rigid insulation member in between. The U-channel or C-channel members may be secured to the rigid insulation member by an adhesive. The U-channel or C-channel members may be overlapping, touching, or separated by a distance.

One side of the wall structure 100 is in contact with an exterior surface (not shown), and the other side of the wall structure 100 is in contact with an interior surface (not shown). The exterior surface may be any type of exterior building material, such as stucco, wood and vinyl siding, concrete, or brick. The interior surface may be any type of interior wall material, such as sheetrock.

FIG. 2A is a schematic drawing of a wall panel or wall structure 200 without openings, and FIG. 2B is a cross sectional view 250 of the wall structure 200 in FIG. 2A according to one embodiment of the invention. The width of the wall structure 200 is approximately 8 or 10 foot wide, however, as will be clear to a person having ordinary skill in the art other widths may be used.

The load bearing members in FIGS. 2A and 2B are similar to those in FIG. 1. Each load bearing member has similar features, therefore, in the interest of brevity only load bearing members 210 a or 210 b will be described. Load bearing members 210 a and 210 b are elongated and typically made from a single integral piece of material. The material is typically any material capable of providing structural support for vertical loading and may also be capable of supporting horizontal loading. In one embodiment, the load bearing members 210 a and 210 b are made from sheet metal, such as galvanized steel or aluminum. In another embodiment, the load bearing members 210 a and 210 b are made from wood. However, as will be clear to a person having ordinary skill in the art, other materials may be used. For instance, in other embodiments, fiberglass or other composite materials are used.

Each load bearing member 210 a typically has a constant cross section along the length of the member 210 a. In one embodiment, the load bearing members 210 a have channel cross sections, such as a C-channel or a U-channel. For instance, FIG. 2B shows C-channel cross sections 211 a and 211 b for load bearing members 210 a and 210 b. In reference to both FIGS. 2A and 2B, the C-channel cross sections 211 a and 211 b of load bearing members 210 a and 210 b, respectively, include a web 214 a and 214 b extending between first legs 215 a and 215 b and second legs 216 a and 216 b, respectively. Looking at cross section 211 a, the first and second legs 215 a and 216 a are substantially perpendicular with the web 214 a. The first leg 215 a is substantially parallel with the second leg 216 a. C-channel cross section 211 a is installed into the wall structure 200 so that its web 214 a is approximately parallel to the web 214 b of C-channel cross section 211 b. In one embodiment, the legs, 215 a, 216 a, 215 b, and 216 b are of the same length.

The C-channel or U-channel may be formed by bending a length of sheet metal along two parallel lines. Typically, between 14 and 25 gauge sheet metal has been found suitable for many applications, although other gauges can be chosen as desired. The gauge of the sheet metal is generally determined by the height of the wall structure or the expected vertical or horizontal loading to be applied to the load bearing member. If the load bearing member is made from a formed material, such as fiberglass or carbon fiber composites, the load bearing members are fully formed before their shape is set by some further action, such as a thermal or chemical reaction. At joint 205, the wall structure 200 intersects with the beginning of another wall structure 201. Two C-channel load bearing members are positioned so that a web of the first load bearing member is adjacent the web of a second load bearing member.

In reference again to FIG. 1, at a first end 102 of the wall structure 100, a corner load bearing member 103 is secured to an insulation member. The corner load bearing member 103 may comprise two C-channels or U-channels, where the legs of the channels face each other. For instance, the legs of a first C-channel load bearing member may overlap or touch the legs of a second C-channel load bearing member. An example of a corner load bearing member is described further in U.S. Patent Application No. 2007/0113506, which is incorporated for all purposes and in its entirety herein.

FIG. 3A is a close up view of a schematic drawing of a portion 206 of the wall structure 200 from FIG. 2; and FIG. 3B is a top down view 208 of the portion 206 of the wall structure in FIG. 3A according to one embodiment of the invention. In reference to FIG. 3A, each load bearing member is secured to a top track 240. In particular, load bearing member 210 b is secured to the top track 240 at joint 217. The load bearing member is typically secured to the top track by a nail or screw, however, other known types of attachment may also be used. As will be clear to a person having ordinary skill in the art, the bottom track, such as the bottom track 142 in FIG. 1, is similarly secured to each load bearing member.

As in FIGS. 2A and 2B, the load bearing members 210 a and 210 b are C-channels, and each insulation member is bonded to each load bearing member. By bonding the insulation member to the load bearing members, a seal is created between the insulation member and the load bearing member. This seal prevents voids between the insulation members and the load bearing members. Therefore, the thermal properties of the wall structure as a whole increase. Similarly, the wall structure is able to absorb sound more easily. Additionally, the seal provided by bonding the insulation members to the load bearing members assists in preventing moisture from entering the wall structure and causing damage within the wall. The structural integrity of the wall increases as well. For instance, the sheer capacity and the lateral strength of the wall structure is greater over wall structures used in the prior art.

FIG. 3B shows first and second legs 215 b and 216 b of the load bearing member 210 b, however, from a top view, this is typically not visible as the top track will cover all or portions of the first and second leg 215 b and 216 b. As will be explained further below, an outer surface of the first and second leg 215 b and 216 b of the load bearing member 210 b is flush with the insulation member 220. Each of the top and bottom tracks may be two L-channels, one leg of the L-channel on a top of the wall structure and the other leg of the L-channel on a side of the wall structure. For instance, FIGS. 3A and 3B show the top track 240 as being two separate L-channels 241 and 242, one on each side of the wall structure 200. In another embodiment, each of the top and bottom tracks may be a single C-channel, where the web extends along the top surface of the wall panel and the legs extend along the side of the wall panel.

FIG. 4 is a cross section of an insulation member 400 according to one embodiment of the invention. The insulation member 400 may be formed from any material having suitable thermal conductivity, such as less than 0.1 W/mK. In addition, the insulation member may be formed from any material having suitable sound absorption properties. As stated above, the insulative material is a rigid or semi-rigid material. In one embodiment, the insulation members are preformed blocks made from expanded or extruded polystyrene. In another embodiment, the insulation member is made from polyisosanurate. Because polyisosanurate is a relatively soft material, it may require paper to surround the material. In other embodiments, insulative mixtures, such as a mixture of mud and straw, may be used as the insulation member.

The cross section of the insulation member 400 has a first end 401 and a second end 402. The cross section of the insulation member typically has a width approximately equal to a length of the web of the load bearing member. In one embodiment, the width, W, of the insulative material 400 is approximately 6 inches. A length, L, of the cross section of the insulation member 400 is generally equal to the desired distance between the load bearing members. In one embodiment, the length of the insulation member 400 is approximately 15⅞ inches. However, as will be clear to a person having ordinary skill in the art, the dimensions of the insulation member and the load bearing member may vary. The insulative material 400 has cutouts to allow for the load bearing member to fit within the insulative material 400 so that the load bearing member and the insulative material are flush with one another. For instance, in one embodiment the first end 401 of the insulative material comprises two notches 410 and 411. The notches 410 and 411 extend an entire vertical length (not shown) of the insulative material 400. Typically, the notches 410 and 411 have dimensions similar to the dimensions of the legs 215 b and 216 b of the load bearing member 210 b in FIGS. 3A and 3B. This is so that an outside edge of the leg of a load bearing member and an outside edge of the insulative material may be generally flush with one another. For instance, in one embodiment each notch 410 and 411 removes ½ inch from the width of the cross section of the insulative material 400 and removes 1½ inches from the length. In another embodiment, each notch 410 and 411 removes ⅜ inch from the width of the cross section of the insulative material 400.

In one embodiment, an air gap between the outer surface of the wall structure 200 and an exterior surface (not shown) may be provided to create a thermal break. Air is known to have low thermal conductivity and thus, an air gap reduces the thermal transmission through the load bearing members 210 a and 210 b. In one embodiment and in reference to FIGS. 3A and 3B, the air gap between the wall structure 200 and the exterior surface is generated by placing hat channels 246 horizontally across the wall structure 200. In particular, FIG. 3A shows the hat channel 246 attached to the outer surface of the wall structure. FIG. 5 shows a cross section of a hat channel 246 according to one embodiment of the invention. The hat channel 246 is ⅞ inch tall. Thus, the hat channel 246 applied to the outer surface of the wall structure 200 in FIGS. 3A and 3B would create an air gap of about ⅞ between the outer surface of a wall structure 200 and an exterior surface. However, as will be clear to a person of ordinary skill in the art, other dimensions for the hat channel may be used.

In another embodiment, a barrier may be used to reduce the thermal transmission through the load bearing members 210 a and 210 b. The barrier is secured to the outer surface of the wall structure 200 between the wall structure 200 and the exterior surface. The barrier has a low thermal conductivity, such as less than 0.1 W/mK. In one embodiment, the barrier material is polystyrene. The polystyrene may be extruded or expanded. In one embodiment the polystyrene is ½ inch thick and may be applied in sheets. The sheets may be of varying size. In one embodiment, the sheet is 4 feet×8 feet or 4 feet by 10 feet. The exterior surface is secured to the outer surface of the barrier material. Both the air gap or the barrier reduce the thermal transmission through the wall structure, particularly through the load bearing members.

By utilizing the entire wall systems described above, the wall structure will have improved structural integrity, thermal resistance, and sound absorption properties. In particular, a wall structure comprising the corner studs, king studs, beam, and structural members therebetween will greatly improve the structural integrity, thermal resistance, and sound absorption over wall structure found in the prior art.

Although the present invention has been described with reference to the disclosed embodiments, persons skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. Such modifications are well within the skill of those ordinarily skilled in the art. Accordingly, the invention is not limited except as by the appended claims. 

1. A wall structure, comprising: an opening; a beam positioned above the opening and having a first load bearing member and a second load bearing member separated from the first load bearing member, a rigid insulation member between the first and second load bearing members; first and second vertical longitudinal supports, the supports being separated horizontally and creating a space therebetween; and a rigid insulation member placed within the space and bonded to the first and second vertical longitudinal supports.
 2. The wall structure of claim 1 wherein at least one of the first and second vertical longitudinal supports has a constant cross-section throughout its length.
 3. The wall structure of claim 2 wherein the constant cross-section is a C-section or a U-section.
 4. The wall structure of claim 2 wherein the bond provides a seal between the insulation member and the first and second vertical longitudinal supports.
 5. The wall structure of claim 1 wherein the rigid insulation member is made from a plastic material.
 6. The wall structure of claim 5 wherein the rigid insulation member comprises an expandable plastic material.
 7. The wall structure of claim 6 wherein the rigid insulation member is made from polystyrene.
 8. The wall structure of claim 1 wherein the rigid insulation member is bonded to the first and second vertical longitudinal supports by an adhesive.
 9. The wall structure of claim 1 wherein the rigid insulation member comprises a cutout so that an outer surface the insulation member is flush with an outer surface of the supports.
 10. The wall structure of claim 9 wherein the cutout in the rigid insulation member has a constant cross section throughout its length.
 11. The wall structure of claim 1 wherein the wall structure comprises an outer surface and an inner surface, the outer surface operable to be coupled to an exterior surface, the outer surface of the wall structure and the exterior surface having at least a partial air gap therebetween.
 12. A wall panel, comprising: a rigid insulation member having a longitudinal length and a first surface along the longitudinal length and a second surface opposite the first surface, the first surface having cut outs along edges of the longitudinal length; a first load bearing member having two parallel plates separated by a back plate secured to the first surface of the insulation member so that the two parallel plates fit into the cut outs along the edges of the longitudinal length; and a second load bearing member secured to the second surface of the insulation member.
 13. The wall panel of claim 12 wherein the insulation member comprises a polystyrene insulation member.
 14. The wall panel of claim 12 wherein the first and second load bearing members are secured to the first and second surfaces of the insulation member, respectively, by an adhesive.
 15. The wall panel of claim 12 wherein the first load bearing member is a C-channel having a web with a first end and a second end, the first end of the web coupled to a first leg and the second end of the web coupled to a second leg.
 16. The wall panel of claim 12 wherein a third and fourth surface of the insulation member are perpendicular to the first surface and the third and fourth surfaces are flush with outer surfaces of the first load bearing member.
 17. The wall panel of claim 12 further comprising a barrier secured to an outer surface of the wall panel.
 18. A method for erecting a wall structure, comprising: providing a rigid insulation member having a first surface and a second surface opposite the first surface, each surface having a longitudinal length, the first surface having a first end and a second end, the first end and second ends parallel with the longitudinal length; removing a portion of the rigid insulation member along the longitudinal length of the first and second ends of the first surface; bonding the first surface of the rigid insulation member to a first longitudinal support so that an outer surface of the longitudinal support is flush with a side surface of the rigid insulation member; and bonding the second surface of the rigid insulation member to a second longitudinal support.
 19. The method of claim 18 wherein the rigid insulation member is expanded polystyrene.
 20. The method of claim 18 wherein the first and second longitudinal supports have a constant cross section throughout their length.
 21. The method of claim 18 wherein the constant cross-section is a C-section or a U-section.
 22. The method of claim 21 wherein an outer edge of a leg of the C-section or U-section is flush with the side surface of the insulation member.
 23. The method of claim 18 further comprising securing a barrier to one surface of the rigid insulation member, the first longitudinal support, and the second longitudinal support.
 24. The method of claim 18 wherein the barrier is made from polystyrene. 